Stepped electrode assembly having predetermined a thickness ratio in the interface between electrode units, battery cell and device comprising the same

ABSTRACT

There are provided an electrode assembly, and a battery cell, a battery pack, and a device. The electrode assembly includes a combination of two or more types of electrode units having different areas, wherein the electrode units are stacked such that steps are formed, and electrode units are formed such that a positive electrode and a negative electrode face one another at an interface between the electrode units.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.14/079,164, filed Nov. 13, 20143, now U.S. Pat. No. 8,945,743, which isa continuation of International Application No. PCT/KR2013/002142, filedMar. 15, 2013, which claims the benefit of Korean Application Nos.10-2012-0041474, filed Apr. 20, 2012, 10-2012-0125636, filed Nov. 7,2012, 10-2012-127013, filed Nov. 9, 2012, 10-2013-0014722, filed Feb. 8,2013, and 10-2013-0028288, filed Mar. 15, 2013 in the KoreanIntellectual Property Office, the disclosures of which are incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention relates to an electrode assembly, and a batterycell and a device comprising the same, and more particularly, to anelectrode assembly including a combination of two or more types ofelectrode units having different areas, in which the electrode units arestacked such that steps are formed, a positive electrode and a negativeelectrode face at an interface between the electrode units.

BACKGROUND OF THE INVENTION

Recently, due to the technological development of mobile devices andincreasing demand therefor, demand for rechargeable batteries (orsecondary batteries) has rapidly increased, and accordingly, a secondarylithium battery having high energy density and a high operating voltage,as well as excellent charge and life span characteristics has beenwidely used as an energy source of various electronic products as wellas various mobile devices.

In general, a secondary lithium battery has a structure in which anelectrode assembly and electrolyte are hermetically sealed within abattery case, and may be classified as a cylindrical battery, aprismatic battery, a pouch-type battery, or the like, according toappearance, and may be classified as a lithium ion battery, a lithiumion polymer battery, a lithium polymer battery, or the like, accordingto a type of electrolyte used therein. Due to the recent trend to reducethe size of mobile devices, demand for thin prismatic batteries andpouch-type batteries has been on the rise, and in particular, interestin easily deformable, lightweight pouch-type batteries has beenincreased.

An electrode assembly received in a battery case may be divided into ajelly-roll type electrode assembly (or a spirally-rolled type electrodeassembly), a stacked-type electrode assembly, a stacked-and-folded-typeelectrode assembly (or a composite-type electrode assembly) according tothe shape of the electrode assembly. In general, the jelly-roll typeelectrode assembly refers to an electrode assembly fabricated by coatingan electrode active material on metal foil used as a current collector,pressing the same, cutting it into a band form having a desired widthand length, partitioning a negative electrode and a positive electrodeby using a separation film, and winding the same in a spiral manner. Thestacked-type electrode assembly refers to an electrode assemblyfabricating by stacking a negative electrode, a separator, and apositive electrode vertically. The stacked-and-folded-type electrodeassembly refers to an electrode assembly fabricated by rolling orfolding a continuous single layer of separator having one or moreelectrodes or electrode laminates comprised of negativeelectrode/separator/positive electrode by an elongated sheet typeseparation film.

However, the related art electrode assemblies known to date aregenerally fabricated in a manner of stacking unit cells or individualelectrodes having the same size, degrading a degree of freedom in shape,to result in a great deal of design restrictions.

Thus, in order to realize various designs, methods of manufacturing abattery having a stepped portion by stacking electrodes having differentsizes or unit cells have been proposed. However, batteries having astepped portion, that have been proposed to date, are manufactured by amethod in which positive electrode plates and negative electrode platesare cut to have desired areas to allow unit cells to have differentareas and stacking the cut positive electrode plates and the cutnegative electrode plates. At this time, since the area in each steppedportion is controllable but the thickness of the stepped portion islimited to multiples of the thickness of each stepped portion, thedesign freedom in designing the thickness direction of the batteries islimited.

Also, the above-described existing techniques only propose ideas thatmay change the design by cutting negative electrode plates and positiveelectrode plates to have desired sizes to form unit cells havingdifferent sizes, and stacking the cut negative electrode plates and thecut positive electrode plates, and do not propose a concrete method thatmay allow a battery having battery characteristics that are actuallyusable to be manufactured. For example, in the case of a battery havinga stepped portion, although each unit cell constituting the battery andhaving a different size operates without error, it is common that thebattery cannot actually be used, due to problems in which it isimpossible to operate these batteries according to the configuration ofunit cells constituting each stepped portion when the electrodes arestacked, battery capacitance is remarkably low compared to otherbatteries having the same volume, or severe swelling occurs at aninterface between stepped portions, thus severely shortening productlifespan. However, these existing batteries having a stepped portion arenot configured in consideration of the above-described problem.

Thus, there is a need for an electrode assembly capable of exhibitinglarge capacity characteristics while implementing various designsaccording to shapes of devices to which a battery cell is applied, andthe development of a battery using the same are required.

SUMMARY OF THE INVENTION

An aspect of the present invention provides an electrode assemblycapable of having various designs implemented therein, including severaladvantages such as, for example, being thinner, and having excellentelectrical capacity characteristics, and an electric cell and devicecomprising the same.

According to an aspect of the present invention, there is provided anelectrode assembly including a combination of two or more types ofelectrode units having different areas, in which the electrode units arestacked such that steps are formed, and electrode units are formed suchthat electrodes having different polarities, i.e., a positive electrodeand a negative electrode, face one another at an interface between theelectrode units having different areas.

According to an aspect of the present invention, the electrode assembly,subject to 500 charge and discharge cycles at 25° C., may have a levelof electrical capacitance above 60% of that after a single charge anddischarge cycle, and a total thickness variation ratio of the electrodeassembly may not be greater than 15%. For this, the positive electrodeand the negative electrode facing each other at the interface betweenthe electrode units having different areas may be configured to bebalanced with each other.

In one embodiment, at the interface between the electrode units havingdifferent areas, a negative electrode of an electrode unit having arelatively large area and a positive electrode of an electrode unithaving a relatively small area may face one another. Thus, in theillustrated embodiments, it be noted that because the negative electrodeat an interface between electrode units having different areas is largerthan the adjacent positive electrode, a portion of the negativeelectrode will be exposed at the interface.

The electrode assembly according to an embodiment of the presentinvention may be configured to satisfy Equation 1:N _(n) /P _(n) ≦N _(n) /P _(n+1),  Equation 1:

where n is an integer not less than 1, N_(n) is reversible capacitanceper unit area of the negative electrode of the electrode unit that isthe n-th largest in area, P_(n) is a reversible capacitance per unitarea of the positive electrode of the electrode unit that is the n-thlargest in area, and P_(n+1) is a reversible capacitance per unit areaof the positive electrode of the electrode unit that is the (n+1)thlargest in area.

When the electrode assembly according to an embodiment of the presentinvention includes three or more types of electrode unit havingdifferent areas, the electrode assembly may be configured to satisfyEquation 2:N _(n) /P _(n) ≦N _(n) /P _(n+1) ≦N _(n+1) /P _(n+1) ≦N _(n+1) /P_(n+2),  Equation 2:

where n is an integer not less than 1, N_(n) is reversible capacitanceper unit area of a negative electrode of the electrode unit that is then-th largest in area, N_(n+1) is reversible capacitance per unit area ofa negative electrode of the electrode unit that is the (n+1)th largestin area, P_(n) is reversible capacitance per unit area of a positiveelectrode of the electrode unit that is the n-th largest in area,P_(n+1) is reversible capacitance per unit area of the positiveelectrode of the electrode unit that is the (n+1)th largest in area, andP_(n+2) is reversible capacitance per unit area of a positive electrodeof an electrode unit that is the (n+2)th largest in area.

When the electrode assembly according to an embodiment of the presentinvention includes three or more types of electrode unit havingdifferent areas, and the electrode unit that is the (n+2)th largest inarea is disposed between the electrode unit that is the n-th largest inarea and the electrode unit that is (n+1)th largest in area, theelectrode assembly may be configured to satisfy Equation 3:N _(n) /P _(n+2) ≦N _(n+1) /P _(n+2)  Equation 3:

where n is an integer not less than 1, N_(n) is reversible capacitanceper unit area of a negative electrode of the electrode unit that is then-th largest in area, N_(n+1) is reversible capacitance per unit area ofa negative electrode of the electrode unit that is the (n+1)th largestin area, P_(n+1) is reversible capacitance per unit area of the positiveelectrode of the electrode unit that is the (n+1)th largest in area, andP_(n+2) is reversible capacitance per unit area of a positive electrodeof an electrode unit that is the (n+2)th largest in area.

The electrode assembly according to an embodiment of the presentinvention may be configured to satisfy Equation 4:dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1)  Equation 4:

where n is an integer not less than 1, dN_(n) is a thickness of thenegative electrode of the electrode unit that is the n-th largest inarea, dP_(n) is a thickness of the positive electrode of the electrodeunit that is the n-th largest in area, and dP_(n+1) is a thickness ofthe positive electrode of the electrode unit that is the (n+1)th largestin area.

When the electrode assembly according to an embodiment of the presentinvention includes three or more types of electrode unit havingdifferent areas, the electrode assembly may be configured to satisfyEquation 5:dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1) ≦dN _(n+1) /dP _(n+1) ≦dN _(n+1)/dP _(n+2)  Equation 5:

where n is an integer not less than 1, dN_(n) is a thickness of thenegative electrode of the electrode unit that is the n-th largest inarea, dN_(n+1) is a thickness of the negative electrode of the electrodeunit that is the (n+1)th largest in area, dP_(n) is a thickness of thepositive electrode of the electrode unit that is the n-th largest inarea, dP_(n+1) is a thickness of the positive electrode of the electrodeunit that is the (n+1)th largest in area, and dP_(n+2) is a thickness ofthe positive electrode of the electrode unit that is the (n+2)th largestin area.

When the electrode assembly according to an embodiment of the presentinvention includes three or more types of electrode unit havingdifferent areas, and the electrode unit that is the (n+2)th largest inarea is disposed between the electrode unit that is the n-th largest inarea and the electrode unit that is (n+1)th largest in area, theelectrode assembly may be configured to satisfy Equation 6:dN _(n) /dP _(n+2) ≦dN _(n+1) /dP _(n+2),  Equation 6:

where n is an integer not less than 1, dN_(n) is a thickness of thenegative electrode of the electrode unit that is the n-th largest inarea, dN_(n+1) is a thickness of the negative electrode of the electrodeunit that is the (n+1) th largest in area, dP_(n+1) is a thickness ofthe positive electrode of the electrode unit that is the (n+1)th largestin area, and dP_(n+2) is a thickness of the positive electrode of theelectrode unit that is the (n+2)th largest in area.

In the electrode assembly according to an embodiment of the presentinvention including a positive electrode and a negative electrode facingeach other at an interface between electrode units having differentareas, the ratio of the thickness of the negative electrode to thethickness of the positive electrode may be in a range of about 0.5 toabout 2, for example, within a range of about 0.6 to about 1.9, about0.8 to about 1.5, or about 1.0 to about 1.5, and more concretely, may beabout 1.0, about 1.1, about 1.2, about 1.3, or about 1.4.

In the electrode assembly according to an embodiment of the presentinvention including a positive electrode and a negative electrode facingeach other at an interface between electrode units having differentareas, the ratio of reversible capacitance per unit area of the negativeelectrode to the reversible capacitance per unit area of the positiveelectrode may be not less than about 1, for example, may be within arange of about 1 to about 2, about 1 to about 1.5, about 1 to about 1.2,about 1 to about 1.1, about 1.5 to about 2, about 1 to about 1.09, about1.02 to about 1.2, about 1.02 to about 1.09, or about 1.05 to about1.09, and more concretely, may be about 1.05, about 1.06, about 1.07,about 1.08, or about 1.09.

The electrode assembly according to an embodiment of the presentinvention includes a combination of three or more types of electrodeunits having different areas, and in this case, the ratios of thereversible capacitances per unit area of the negative electrodes to thereversible capacitances per unit area of the positive electrodes in theinterface between the electrode units may be the same as each other orincrease as the contact area between the electrode units is reduced.

Meanwhile, in an embodiment of the present invention, the electrode unitmay include: one or more single electrodes; one or more unit cellsincluding at least one positive electrode, at least one negativeelectrode, and at least one separator; or any combinations thereof. Inthis case, the unit cell may be selected from the group consisting of ajelly-roll type unit cell, a stacked-type unit cell, alaminated-and-stacked type unit cell and a stacked-and-folded-type unitcell. In the unit cell, polarities of two electrodes disposed on bothoutermost surfaces may be the same or different.

Also, preferably, the electrode assembly according to an embodiment ofthe present invention may have a structure in which some or all of theelectrodes and the unit cells constituting the electrode units may bewrapped with a long sheet-type separation film.

Meanwhile, the electrode unit according to an embodiment of the presentinvention may have various sectional shapes. For example, a section ofthe electrode unit according to an embodiment of the present inventionmay have a quadrangular shape, a quadrangular-like shape with at leastone corner having a curved shape, a trapezoid shape, or a shape with atleast one or more sides having a curved shape.

Also, the electrode assembly according to an embodiment of the presentinvention may include a combination of electrode units having differentsectional shapes or may include a combination of electrode units havingthe same sectional shape.

Meanwhile, the electrode units according to an embodiment of the presentinvention may include one or more electrode tabs, and in this case, theelectrode tabs having the same polarity may be connected. In this case,the electrode tabs may have the same size, or may have different sizesaccording to areas of the electrode units.

Meanwhile, in the electrode assembly according to an embodiment of thepresent invention, two or more types of electrode units having differentareas may be stacked in various arrangements. A method for stacking theelectrode units may not be particularly limited. For example, theelectrode units may be stacked to have an arrangement in which the areasof the electrode units are reduced upwardly, or conversely, theelectrode units may be stacked to have an arrangement in which the areasof the electrode units are increased upwardly. Alternatively, theelectrode units may be stacked such that an electrode unit having thelargest area is arranged in a middle layer of the electrode assembly.

Also, in the electrode assembly according to an embodiment of thepresent invention, the electrode units may be stacked to have anarrangement in which central points of the respective electrode units inthe plane direction are consistent, may be stacked to have anarrangement in which the central points of the respective electrodeunits in the plane direction are spaced apart at certain intervals, ormay be stacked to have an arrangement in which one corners of therespective electrode units are consistent.

According to another aspect of the present invention, there is provideda battery cell in which the foregoing electrode assembly according to anembodiment of the present invention is installed in a battery case.Here, the battery case may be a pouch-type case, but the presentinvention is not limited thereto. Also, the battery case may be formedto have a shape corresponding to a shape of the electrode assembly.Also, the battery cell according to an embodiment of the presentinvention may be a lithium ion secondary battery or a lithium ionpolymer secondary battery.

According to another aspect of the present invention, there is provideda device including one or more of the battery cells. A system componentof the device may be positioned in surplus space within the batterycell. The device may be a portable phone, a portable computer, a smartphone, a smart pad, a net book, a light electronic vehicle (LEV), anelectric vehicle, a hybrid electric vehicle, a plug-in hybrid electricvehicle, or a power storage device.

According to an embodiment of the present invention, an electrodeassembly may have more various designs than the existing electrodeassemblies by using combinations of two or more types of electrodeunits, and have commercially available electrical capacitance anddurability characteristics.

Also, since an electrode assembly according to an embodiment of thepresent invention may achieve a balance between a positive electrode anda negative electrode at an interface between electrode units havingdifferent areas to relatively freely control thicknesses as well asareas of the electrode units constituting each stepped portion whilemaintaining the capacitance characteristic and the durabilitycharacteristic, the design freedom is very superior. As a result, a deadspace which is generated due to a design factor when installing a devicemay be minimized to achieve superior space usability.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of an electrode assembly according to a firstembodiment of the present invention;

FIG. 2 is a side view of an electrode assembly according to a secondembodiment of the present invention;

FIG. 3 is a side view of an electrode assembly according to a thirdembodiment of the present invention;

FIG. 4 is a side view of an electrode assembly according to a fourthembodiment of the present invention;

FIG. 5 is a side view of an electrode assembly according to a fifthembodiment of the present invention;

FIG. 6 is a deployment view of an electrode assembly according to asixth embodiment of the present invention;

FIG. 7 is a view illustrating a configuration of electrode tabsaccording to an embodiment of the present invention;

FIG. 8 is a view illustrating an example of stacking electrode unitsaccording to an embodiment of the present invention;

FIG. 9 is a perspective view of a battery cell according to anembodiment of the present invention;

FIG. 10 is a perspective view of a battery cell according to anotherembodiment of the present invention;

FIG. 11 is a graph showing an electrical capacitance and a thicknessvariation ratio after 500 charge and discharge cycles of electrodeassemblies of Examples 1 and 2 and Comparative Examples 1 and 2.

FIG. 12 is a graph showing an energy density variation with a reversiblecapacitance ratio of a negative electrode to a positive electrode at aninterface between electrode units.

FIG. 13 is a graph showing an energy density variation with a thicknessratio of negative electrode/positive electrode at an interface betweenelectrode units.

FIGS. 14 through 16 are schematic views illustrating implementationexamples of laminated-and-stacked-type unit cells.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter, embodiments of the present invention will be described indetail with reference to the accompanying drawings. However, drawingsbelow are illustrative drawings provided to help understand the presentinvention merely as an embodiment of the present invention and the scopeof the present invention is not limited thereto. Some components may beexaggerated, reduced, or omitted to easily understand the presentinvention.

An electrode assembly according to an embodiment of the presentinvention includes a combination of two or more types of electrode unitshaving different areas, in which the electrode units are stacked suchthat steps are formed, and electrodes having different polarities, i.e.,a positive electrode and a negative electrode, are formed to face at aninterface between the electrode units having different areas.

Here, the ‘area’ refers to a surface area of the electrode units in adirection perpendicular to a direction in which the electrode units arestacked.

Also, the ‘electrode unit’ refers to a basic unit constituting one layerof the electrode assembly having steps according to an embodiment of thepresent invention, and each of the electrode units may include:electrodes such as a negative electrode or a positive electrode; one ormore unit cells including at least one positive electrode, at least onenegative electrode, and at least one separator, or a combinationthereof.

Meanwhile, the term ‘unit cell’ is a concept including all of electrodelaminates including at least one negative electrode, at least onepositive electrode, and at least one separator, and a method forstacking a negative electrode, a positive electrode, and a separator ina unit cell is not particularly limited. For example, in an embodimentof the present invention, the term ‘unit cell’ may be understood toencapsulate a concept including all of an electrode laminate fabricatedaccording to a jelly-roll scheme of partitioning a sheet-type negativeelectrode and a sheet-type positive electrode by using a separator andbeing wound in a spiral manner; an electrode laminate fabricatedaccording to a stacking scheme of sequentially stacking one or morenegative electrodes, one or more separators, and one or more positiveelectrodes; or an electrode laminate fabricated according to astacking-and-folding scheme of disposing electrodes and/or electrodelaminates formed by stacking one or more positive electrodes,separators, and negative electrodes, on an elongated sheet-typeseparation film, and folding the same.

Meanwhile, according to an embodiment of the present invention, in theunit cells like positive electrode/separator/negativeelectrode/separator/positive electrode, a negativeelectrode/separator/positive electrode/separator/negative electrode, theelectrodes disposed on both outermost surfaces of the unit cell may havethe same polarity, or like positive electrode/separator/negativeelectrode or positive electrode/separator/negativeelectrode/separator/positive electrode/separator/negative electrode,electrodes disposed on both outermost surfaces of the unit cell may havethe opposite polarities.

Meanwhile, in the present invention, it should be understood that theelectrode laminate manufactured in the stacked manner is a conceptincluding an electrode laminate, manufactured by a method (hereinafterreferred to as ‘lamination and stacking method’) of laminating at leastpositive electrode, at least one negative electrode, and at least oneseparator to form an electrode unit body and then stacking theseelectrode unit bodies as well as the electrode laminate, manufactured bya typical method of sequentially stacking a positive electrode, aseparator, and a negative electrode.

Meanwhile, in the case in which an electrode laminate is manufactured bythe lamination and stacking method, the electrode unit body may be usedif it includes at least positive electrode, at least one negativeelectrode and at least one separator, and the configuration of theelectrode unit body is not particularly limited.

However, from both points of view of process simplicity and economicfeasibility, when an electrode laminate is manufactured by thelamination and stacking method, it is desirable that the electrode unitbody be configured to include a basic structure comprised of a firstelectrode/separator/second electrode/separator or a separator/firstelectrode/separator/second electrode. In this regard, the firstelectrode and the second electrode may be a positive electrode and anegative electrode having opposing polarities, respectively, and theelectrode unit body may include one or two or more basic structures.

Meanwhile, the electrode laminate, manufactured by the lamination andstacking method may only be comprised of an electrode unit bodyincluding the above-described basic structure, or may include acombination of an electrode unit body having the basic structure and anelectrode structure body having a different structure.

FIGS. 14 through 16 illustrate various examples of electrode laminatemanufactured by the lamination and stacking method.

In FIG. 14, there is illustrated a laminated and stacked-type electrodelaminate comprised of electrode unit bodies 710 having a basic structureof a separator 60/negative electrode 50/separator 60/positive electrode40. While FIG. 14 illustrates the basic structure of aseparator/negative electrode/separator/positive electrode, the positionsof the positive electrode and the negative electrode may be exchangedwith each other, thus providing a basic structure of aseparator/positive electrode/separator/negative electrode. Meanwhile, asillustrated in FIG. 14, in the case in which the electrode unit body hasthe basic structure of a separator/negative electrode/separator/positiveelectrode, since the positive electrode may be exposed without theseparator at the outermost side of the stacked electrode body, it may bedesirable, in terms of an electrode design considering capacitance, touse a one surface-coated positive electrode in which an active materialis not coated on the exposed surface of the outermost side, as thepositive electrode. Meanwhile, while FIG. 14 illustrates that theelectrode unit bodies have only one basic structure, the presentinvention is not limited thereto, and a configuration in which at leasttwo basic structures are repeatedly stacked may be used as one electrodeunit body.

In FIG. 15, there is illustrated an electrode laminate in whichelectrode unit bodies 810 having a basic structure of separator60/negative electrode 50/separator 60/positive electrode 40, and anelectrode structure body 820 having a structure of separator 60/negativeelectrode 50/separator 60 are stacked. When the electrode structure bodyhaving the structure of separator 60/negative electrode 50/separator 60is stacked as illustrated in FIG. 15, the positive electrode 40 may beprevented from being exposed to the outside, and electrical capacitancemay be increased. Similarly to this, in the case of a configuration inwhich a negative electrode is disposed at the outermost side of anelectrode unit body, an electrode structure body comprised ofseparator/positive electrode/separator may be stacked thereon, so thatthe capacitance of the negative electrode may be used to the maximum.

In FIG. 16, there is illustrated an electrode laminate in whichelectrode unit bodies 810′ having a basic structure of negativeelectrode 50/separator 60/positive electrode 40/separator 60, and anelectrode structure body 820′ having a structure of negative electrode50/separator 60/positive electrode 40/separator 60/negative electrode 50are stacked. When the electrode structure body 820′ having the structureof negative electrode 50/separator 60/positive electrode 40/separator60/negative electrode 50 is stacked on the outermost surface of theelectrode laminate as illustrated in FIG. 16, the positive electrode maybe prevented from being exposed to the outside, and electricalcapacitance may be increased.

As illustrated in FIGS. 15 and 16, the electrode laminate which aremanufactured by the lamination and stacking method may use combinationsof a single electrode, a separator, or unit cells having differentarrangements and configurations from the above-described electrode unitbodies, together with the electrode unit bodies having theabove-described basic structure. In particular, when electrode unitbodies having the basic structure are stacked, in an aspect ofpreventing the positive electrode from being exposed to the outsideand/or in an aspect of enhancing the battery capacitance, a singleelectrode, a one surface-coated electrode, a separator, or unit cellshaving different arrangement and configuration from the above-describedunit bodies may be disposed on one outermost surface and/or bothoutermost surfaces of the electrode laminate. While FIGS. 15 and 16illustrate that an electrode structure body having a different structureis arranged in upper side of electrode laminate, the present inventionis not limited thereto, and if necessary, an electrode structure bodyhaving a different structure may be arranged in lower side of theelectrode laminate, or electrode structure bodies having differentstructures may be arranged in both of upper side and lower side ofelectrode laminate.

Meanwhile, in an embodiment of the present invention, the term ‘stackingand folding’ generally refers to a method of disposing electrodes and/orelectrode laminates formed by stacking one or more positive electrodes,separators, and negative electrodes on an elongated sheet-typeseparation film and folding the same. Here, the folding method is notparticularly limited and the folding method should be understood to havea concept covering any folding methods well known in the art, e.g., amethod of folding a sheet-type separation film in zigzags (known as aZ-folding type or a folding screen type), a method of disposingelectrode laminates formed by stacking one or more negative electrodesand positive electrodes with a separator interposed therebetween on onesurface of a sheet-type separation film, and winding and rolling thesame, or a method of alternately disposing electrodes on both surfacesof a sheet-type separation film and winding and rolling the sheet-typeseparation film. In the present disclosure, a unit cell fabricatedaccording to the jelly-roll method will be referred to as ajelly-roll-type unit cell, a unit cell fabricated according to thestacking method will be referred to as a stacked-type unit cell, and aunit cell fabricated according to the stacking-and-folding method willbe referred to as a ‘stacked-and-folded-type unit cell’ for the purposesof description.

In the electrode assembly according to an embodiment of the presentinvention, two or more types of electrode units having different areasare stacked such that steps are formed, thus implementing batterieshaving various shapes in comparison to the related art. In an embodimentof the present invention, a difference in the areas of the electrodeunits may be as large as to form steps when the electrode units arestacked, and may be freely adjusted in consideration of a desired designof a battery, or the like, without being particularly limited. Forexample, in an implementation example of the present invention, when twoelectrode units included in the electrode assembly are compared, if anarea of an electrode unit having a relatively large area is about 100%,an electrode unit having a relatively small area may have an area withina range of about 20% to about 95%, preferably, within an range of about30% to about 90%.

Meanwhile, in the electrode assembly according to an embodiment of thepresent invention, thicknesses of the respective electrode units may bethe same or different and are not particularly limited. For example, inan embodiment of the present invention, the electrode unit having arelatively large area may have a thickness smaller than that of theelectrode unit having a relatively small area or may have a greaterthickness.

Meanwhile, in the electrode assembly according to an embodiment of thepresent invention, since the electrodes having different polarities aredisposed to face one another at the interface between the electrodeunits having different areas, electricity can be stored even at theinterface between the electrode units, and as a result, electricitycapacity is increased. In this case, ‘facing’ refers to a disposition ina facing direction, and in this case, two facing electrodes are notrequired to be in contact, and has a concept of including a case inwhich different components, e.g., a separator and/or a sheet-typeseparation film, may be interposed between two electrodes.

Meanwhile, preferably, the electrode assembly according to an embodimentof the present invention may be formed such that a negative electrode ofan electrode unit having a larger area and a positive electrode of anelectrode having a smaller area face at an interface between the two ormore types of electrode units having different areas. This is because,if the positive electrode of the electrode unit having a larger area isdisposed on the interface between the electrode units having differentareas, lithium may be precipitated from the positive electrode of theelectrode unit having a larger area to shorten a life span of a batteryor degrade stability of the battery.

An electrode assembly according to an embodiment of the presentinvention includes electrode units having different areas, and may berealized in various manners by configuring the respective electrodeunits to be different from each other. It is, however, to be noted thatit is difficult to manufacture an electrode assembly having commerciallyavailable capacitance and durability characteristics by onlymanufacturing electrode units having different areas from each other andstacking the manufactured electrode units, and the design freedom in thethickness direction is very limited because the thickness of theelectrode unit is limited to being a multiple of a thickness of a unitcell or a unit electrode. Thus, the inventors have performed researchinto manufacturing an electrode assembly having commercially availablepower efficiency and structural stability while having excellent designfreedom in the thickness direction, and have found that an electrodeassembly, excellent in terms of capacitance, durability and designfreedom in the thickness direction may be produced by controlling abalance at an interface between electrode units having different areas.

At this time, the balance at the interface between the electrode unitshaving different areas is controlled refers to a positive electrode anda negative electrode facing one another at an interface betweenelectrode units being designed so as to stably maintain power efficiencyand battery stability, and may be achieved, for example, by controllingcapacitances, thicknesses, or the like of the positive electrode and thenegative electrode at the interface. More concretely, it is desirable todesign a positive electrode and a negative electrode facing one anotherat an interface between electrode units such that an electrode assemblyof the present invention, which has been subject to 500 charge anddischarge cycles at 25° C., has an electrical capacitance of not lessthan 60% with respect to an electrical capacitance after a single chargeand discharge cycle, and a total thickness variation ratio of theelectrode assembly is not greater than 15%.

In this regard, the electrical capacitance refers to electricalcapacitance measured under the following charging condition (A) anddischarging condition (B). Meanwhile, a pause of 10 minutes is providedbetween charge and discharge cycles.

Charging condition (A): After a battery was charged to 4.25V or 4.35V ina constant current mode of 1 C, the constant current mode was convertedto a constant voltage mode, and the charging was completed after currentflowed until the amount of charge current became 1/20 of a minimumcapacitance of the battery.

Discharging condition (B): A discharge current of 1 C flowed in theconstant current mode, and the discharge was completed when the voltagereached 3V.

Meanwhile, the thickness variation ratio of the electrode assemblyrefers to (total thickness of the electrode assembly after 500 chargeand discharge cycles/a total thickness of the electrode assembly after asingle charge and discharge cycle)×100.

Meanwhile, after research, the inventors have found that the electrodeunits having different areas may be balanced at an interfacetherebetween through a design in which reversible capacitance per unitarea of a negative electrode and a positive electrode facing each otherat the interface between the electrode units having different areassatisfies a specific condition.

More concretely, when reversible capacitance per unit area of a negativeelectrode of an electrode unit that is the n-th largest in area isN_(n), reversible capacitance per unit area of a negative electrode ofan electrode unit that is the (n+1)th largest in area is N_(n+1),reversible capacitance per unit area of a positive electrode of anelectrode unit that is the n-th largest in area is P_(n), and reversiblecapacitance per unit area of a positive electrode of an electrode unitthat is the (n+1)th largest in area is P_(n+1), an electrode assembly ofthe present invention may be formed such that the electrode assembly isconfigured to satisfy the following equation 1.N _(n) /P _(n) ≦N _(n) /P _(n+1),  Equation 1:

where n is an integer not less than 1.

In this regard, the reversible capacitance per unit area of the negativeelectrode refers to a value defined as a charge capacitance of thenegative electrode per unit area [mAh/cm²]×efficiency [%] of thenegative electrode, the charge capacitance of the negative electrode perunit area refers to a value defined as a loaded amount [g/cm²] of anegative electrode active material×a charge capacitance [mAh/g] per unitweight of the negative electrode, and the efficiency of the negativeelectrode refers to a value defined as (a ratio of a dischargecapacitance of the negative electrode to the charge capacitance of thenegative electrode)×100. Also, the reversible capacitance per unit areaof the positive electrode refers to a value defined as a loaded amount[g/cm²] of a positive electrode active material×a charge capacitance[mAh/g] per unit weight of positive electrode−an irreversiblecapacitance [mAh] per unit area of negative electrode.

Meanwhile, the loaded amount of negative electrode active materialrefers to the weight per unit area of the negative electrode activematerial coated on a negative electrode collector, and the loaded amountof the positive electrode active material refers to the weight per unitarea of the positive electrode active material coated on a positiveelectrode collector. Also, the charge capacitances, the dischargecapacitances, and the irreversible capacitances per unit weight ofpositive electrode and negative electrode may be measured by thefollowing methods.

1) Charge Capacitance Per Unit Weight of Positive Electrode

After a positive electrode for evaluation is formed as a half cell, acounter electrode is formed of a lithium metal, the half cell is chargedunder the constant current of 0.1 C, and electrical capacitance ismeasured when an operating electrode potential reaches 4.25V. Then, themeasured electrical capacitance is divided by the weight of an activematerial of the positive half cell to obtain the charge capacitance perunit weight of positive electrode.

2) Charge Capacitance Per Unit Weight of Negative Electrode

After a negative electrode for evaluation is formed as a half cell, acounter electrode is formed of a lithium metal, the half cell is chargedunder the constant current of 0.1 C, and electrical capacitance ismeasured when an operating electrode potential reaches 1.6V. Then, themeasured electrical capacitance is divided by the weight of an activematerial of the negative half cell to obtain the charge capacitance perunit weight of negative electrode.

3) Discharge Capacitance Per Unit Weight of Negative Electrode

After a negative electrode for evaluation is formed as a half cell, acounter electrode is formed of a lithium metal, the half cell is chargedunder the constant current of 0.1 C, and after an operating electrodepotential reaches 1.6V, the half cell is discharged under a constantcurrent of 0.1 C, and electrical capacitance is measured when theoperating electrode potential is 0V. Then, the measured electricalcapacitance is divided by the weight of an active material of thenegative half cell to obtain the charge capacitance per unit weight ofnegative electrode.

4) Irreversible Capacitance Per Unit Weight of Negative Electrode

A difference between the charge capacitance and the dischargecapacitance which are measured with the above-described method isdivided by the weight of the active material of the negative half cellto obtain the irreversible capacitance per unit weight of the negativeelectrode.

Meanwhile, according to the research of the inventors, in the case of anelectrode assembly comprised of electrode units having different areas,although the respective electrode units are designed to operatenormally, when the reversible capacitance ratio in the interface betweenthe electrode units does not satisfy Equation 1, it is shown that it isdifficult to implement commercially viable capacitance and durabilitycharacteristics in the electrode assembly. These results are notanticipated at all in existing electrode assemblies having the samearea, and show that new elements that have not been considered in thecourse of manufacturing the existing electrode assemblies should beconsidered so as to allow an electrode assembly comprised of electrodeunits having different areas to be manufactured. Also, when Equation 1is satisfied, since the thickness of each of the electrode units isrelatively freely controllable within the defined range, design freedomin the thickness direction may be innovatively enhanced.

Meanwhile, when economic feasibility and energy density per volume areconsidered in the electrode assembly of the present invention, theelectrode assembly according to an embodiment of the present inventionmay be configured to satisfy Equation 1-1, preferably to satisfyEquation 1-2.

However, the present invention is not limited to the above values.1≦N _(n) /P _(n) ≦N _(n) /P _(n+1)  Equation 1-1:1≦N _(n) /P _(n) ≦N _(n) /P _(n+1)≦1.2  Equation 1-2:

In Equations 1-1 and 1-2, the definitions of n, M_(n), P_(n), andP_(n+1) are the same as those in Equation 1.

Meanwhile, when an electrode assembly according to an embodiment of thepresent invention includes combinations of three or more types ofelectrode unit having different areas, the electrode assembly ispreferably configured to satisfy Equation 2.N _(n) /P _(n) ≦N _(n) /P _(n+1) ≦N _(n+1) /P _(n+1) ≦N _(n+1) /P_(n+2)  Equation 2:

In Equation 2, n is an integer not less than 1, N_(n) is reversiblecapacitance per unit area of a negative electrode of the electrode unitthat is the n-th largest in area, N_(n+1) is reversible capacitance perunit area of a negative electrode of the electrode unit that is the(n+1)th largest in area, P_(n) is reversible capacitance per unit areaof a positive electrode of the electrode unit that is the n-th largestin area, P_(n+1) is reversible capacitance per unit area of the positiveelectrode of the electrode unit that is the (n+1)th largest in area, andP_(n+2) is reversible capacitance per unit area of a positive electrodeof an electrode unit that is the (n+2)th largest in area.

Meanwhile, when economic feasibility and energy density per volume areconsidered in the electrode assembly of the present invention, theelectrode assembly of the present invention is preferably configured tosatisfy Equation 2-1.1≦N _(n) /P _(n) ≦N _(n) /P _(n+1) ≦N _(n+1) /P _(n+1) ≦N _(n+1) /P_(n+2)  Equation 2-1:1≦N _(n) /P _(n) ≦N _(n) /P _(n+1) ≦N _(n+1) /P _(n+1) ≦N _(n+1) /P_(n+2)≦1.2  Equation 2-2:

In Equations 2-1 and 2-2, the definitions of n, N_(n), N_(n+1), P_(n),and P_(n+1) are the same as those in Equation 2.

Meanwhile, when an electrode assembly according to an embodiment of thepresent invention includes combinations of three or more types ofelectrode unit having different areas and the (n+2)th largest in area isdisposed between the electrode unit that is the n-th largest in area andthe electrode unit that is (n+1)th largest in area, the electrodeassembly is more preferably configured to satisfy Equations 2 and 3 atthe same time.N _(n) /P _(n+2) ≦N _(n+1) /P _(n+2)  Equation 3:

In Equation 3, n is an integer not less than 1, Nn is reversiblecapacitance per unit area of a negative electrode of the electrode unitthat is the n-th largest in area, Nn+1 is reversible capacitance perunit area of a negative electrode of the electrode unit that is the(n+1)th largest in area, P_(n+1) is reversible capacitance per unit areaof a positive electrode of the electrode unit that is the (n+1)thlargest in area, and P_(n+2) is reversible capacitance per unit area ofa positive electrode of the electrode unit that is the (n+2)th largestin area. According to the research of the inventors, when the reversiblecapacitances of the positive electrode and the negative electrodeincluded in the electrode assembly are designed to satisfy theabove-described conditions, while the area and thickness of eachelectrode unit are changed variously, the electrode assembly havingsuperior power efficiency and structural stability, that is, theelectrode assembly in which the electrical capacitance when 500 chargeand discharge cycles have been performed at 25° C. is 60% or more withrespect to the electrical capacitance after a single charge anddischarge cycle, and the total thickness variation ratio of theelectrode assembly is 15% or less can be obtained.

Meanwhile, the electrode assembly according to an embodiment of thepresent invention may be designed such that the ratio of the reversiblecapacitance per unit area of the negative electrode to the reversiblecapacitance per unit area of the positive electrode is not less than 1,and preferably, about 1 to about 2, about 1 to about 1.5, about 1 toabout 1.1, about 1 to about 1.09, about 1.5 to about 2, about 1.02 toabout 1.09, about 1.05 to about 1.09, about 1.05, about 1.06, about1.07, about 1.08 or about 1.09. According to the studies of theinventors, it is found that commercially available battery capacitanceand durability may be obtained while the area, thickness, or the like ofthe electrode unit is relatively freely changed within a rangesatisfying that the ratio of the reversible capacitance per unit area ofthe negative electrode to the reversible capacitance per unit area ofthe positive electrode facing the negative electrode at an interface is1 or more. However, when the ratio of the reversible capacitance perunit area of the negative electrode to the reversible capacitance perunit area of the positive electrode facing the negative electrode at aninterface is less than 1, it is found that swelling is generated andthus battery stability and electrode efficiency are sharply reduced.

Meanwhile, in the case in which an electrode assembly of the presentinvention includes combinations of three or more types of electrode unithaving different areas, the electrode assembly is designed such that theratios of the reversible capacitances per unit area of the negativeelectrodes to the reversible capacitances per unit area of the positiveelectrodes in the interface between the electrode units are the same aseach other or increase as the contact area between the electrode unitsis reduced. That is, in the case in which an electrode assembly includesan electrode unit (for convenience, referred to as first electrode unit)that has the largest area, an electrode unit (for convenience, referredto as second electrode unit) that has a medium area, and an electrodeunit (for convenience, referred to as third electrode unit) that has thesmallest area, it is desirable that the ratio of the reversiblecapacitances per unit area of the positive electrode and the negativeelectrode disposed in the interface between the second electrode unitand the third electrode unit is the same as or greater than the ratio ofthe reversible capacitances per unit area of the positive electrode andthe negative electrode disposed in the interface between the firstelectrode unit and the second electrode unit. When the number of theelectrode units having different areas increases, two or more interfacesbetween the electrode units are generated, and when balances in the twoor more interfaces are not controlled, battery stability and performancemay be reduced due to a structural deformation. According to theresearch of the inventors, in the case in which an electrode assemblyincludes combinations of three or more types of electrode unit havingdifferent areas, when the ratio of the reversible capacitances per unitarea of the positive electrode and the negative electrode disposed inthe interface between the electrode units is configured as describedabove, the reduction in battery stability and performance due tostructural deformation may be suppressed as much as possible.

Meanwhile, another method of balancing the positive electrode and thenegative electrode in the interface between the electrode units havingdifferent areas is to design the electrode assembly such that the ratioof thicknesses of the positive electrode and the negative electrodefacing each other at the interface between the electrode units havingdifferent areas satisfies a specific range. For example, in theelectrode assembly according to an embodiment of the present invention,the ratio (i.e., thickness of negative electrode/thickness of positiveelectrode) of the thickness of the negative electrode to the thicknessof the positive electrode facing the negative electrode at the interfacebetween the electrode units is in a range of about 0.5 to about 2,preferably, in a range of about 0.7 to about 1.8, and more preferablywithin a range of about 1.0 to about 1.4. When the ratio of thethicknesses of the negative electrode and the positive electrode facingeach other at the interface between the electrode units is less than0.5, sites in the negative electrode that may receive lithium ions ofthe positive electrode are deficient, and thus, lithium ions may beprecipitated to exhibit low performance and low capacitance as comparedto designed capacitance, and when the ratio exceeds 2, sites in thenegative electrode that may receive lithium ions in an initial chargeincrease, so that the irreversible capacitance increases, an actualcapacitance is low as compared to a designed capacitance, an excessiveamount of negative electrode is used so that an energy density that isthe efficiency of capacitance to battery density is lowered, a coatingforce is reduced, and a negative electrode active material may bedelaminated.

Meanwhile, the thicknesses of the positive electrode and the negativeelectrode may be measured by cutting the electrode assembly using ionmilling device (cross section polisher (CP)) to expose a section andscanning the exposed section using SEM equipment. At this time, thethicknesses of the positive electrode and the negative electrodeindicate thicknesses including all of the electrode collector and theelectrode coating portion. For example, in the case of a single-surfaceelectrode in which an electrode coating portion is coated on a singlesurface of the electrode, the thickness of the electrode indicates a sumof thicknesses of the coating portion and the electrode collector, andin the case of a dual-surface electrode in which an electrode coatingportion is coated on both surface of the electrode, i.e., in the case ofan electrode comprised of coating portion/collector/coating portion, thethickness of the electrode indicates a sum of thicknesses of two coatingportions and collector.

More concretely, an electrode assembly according to an embodiment of thepresent invention is preferably configured to satisfy Equation 4.dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1)  Equation 4:

where n is an integer not less than 1, dN_(n) is a thickness of thenegative electrode of the electrode unit that is the n-th largest inarea, dP_(n) is a thickness of the positive electrode of the electrodeunit that is the n-th largest in area, and dP_(n+1) is a thickness ofthe positive electrode of the electrode unit that is the (n+1)th largestin area.

Meanwhile, when economic feasibility and energy density per volume areconsidered in the electrode assembly, the electrode assembly accordingto an embodiment of the present invention is preferably configured tosatisfy Equation 4-1, more preferably, the electrode assembly may beconfigured to satisfy Equation 4-2, and most preferably, the electrodeassembly may be configured to satisfy Equation 4-3.0.5≦dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1)≦2  Equation 4-1:0.6≦dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1)≦1.9  Equation 4-2:1.0≦dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1)≦1.5  Equation 4-3:

In Equations 4-1, 4-2, and 4-3, the definitions of dN_(n), dP_(n), anddP_(n+1) are the same as those in Equation 4.

Meanwhile, in the case in which the electrode assembly according to anembodiment of the present invention includes three or more types ofelectrode unit having different areas, the electrode assembly may beconfigured to satisfy Equation 5.dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1) ≦dN _(n+1) /dP _(n+1) ≦dN _(n+1)/dP _(n+2)  Equation 5:

where n is an integer not less than 1, dN_(n) is a thickness of thenegative electrode of the electrode unit that is the n-th largest inarea, dN_(n+1) is a thickness of the negative electrode of the electrodeunit that is the (n+1)th largest in area, dP_(n) is a thickness of thepositive electrode of the electrode unit that is the n-th largest inarea, dP_(n+1) is a thickness of the positive electrode of the electrodeunit that is the (n+1)th largest in area, and dP_(n+2) is a thickness ofthe positive electrode of the electrode unit that is the (n+2)th largestin area.

Meanwhile, when economic feasibility and energy density per volume areconsidered in the electrode assembly, the electrode assembly accordingto an embodiment of the present invention may be preferably configuredto satisfy Equation 5-1, more preferably, the electrode assembly may beconfigured to satisfy Equation 5-2, and most preferably, the electrodeassembly may be configured to satisfy Equation 5-3.0.5≦dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1) ≦dN _(n+1) /dP _(n+1) ≦dN_(n+1) /dP _(n+2)≦2  Equation 5-1:0.6≦dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1) ≦dN _(n+1) /dP _(n+1) ≦dN_(n+1) /dP _(n+2)≦1.9  Equation 5-2:1.0≦dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1) ≦dN _(n+1) /dP _(n+1) ≦dN_(n+1) /dP _(n+2)≦1.5  Equation 5-3:

In Equations 5-1, 5-2, and 5-3, the definitions of dN_(n), dN_(n+1),dP_(n), and dP_(n+1) are the same as those in Equation 5.

Also, in the case in which an electrode assembly of the presentinvention includes three or more types of electrode unit havingdifferent areas, and the electrode unit that is the (n+2)th largest inarea is disposed between the electrode unit that is the n-th largest inarea and the electrode unit that is (n+1)th largest in area, theelectrode assembly according to an embodiment of the present inventionis preferably configured to satisfy Equations 5 and 6 at the same time.dN _(n) /dP _(n+2) ≦dN _(n+1) /dP _(n+2),  Equation 6:

In Equation 6, n is an integer not less than 1, and dN_(n) is thethickness of a negative electrode of an electrode unit that is the n-thlargest in area, dN_(n+1) is the thickness of a negative electrode of anelectrode unit that is the (n+1)th largest in area, dP_(n+1) is thethickness of a positive electrode of the electrode unit that is the(n+1)th largest in area, and dP_(n+2) is the thickness of a positiveelectrode of an electrode unit that is the (n+2)th largest in area.

As above, the method of controlling the thicknesses of the positiveelectrode and the negative electrode in the interface between theelectrode units is advantageous in that it is simple in design, ascompared to the method of controlling the ratio of the reversiblecapacitances. However, in the case in which the specification of a usedelectrode is changed according to the electrode unit, the positiveelectrode and the negative electrode may not only be balanced by theratio of the thicknesses. Therefore, in such a case, it is desirablethat the electrode assembly is designed according to the method ofcontrolling the ratio of the reversible capacitances of the positiveelectrode and the negative electrode. However, when the specificationsof electrodes used in each electrode unit are the same as each other, orwhen the specifications of electrodes are different but the chargecapacitance of a negative electrode active material is about 1.5 to 3times, preferably about 1.8 to 2.5 times greater than the chargecapacitance of a positive electrode active material, the positiveelectrode and the negative electrode may be easily balanced at theinterface between the electrode units by designing the thicknesses ofthe positive electrode and the negative electrode in the above-describedranges.

Meanwhile, each of the positive electrodes and each of the negativeelectrodes included in an electrode assembly according to an embodimentof the present invention are designed to be balanced at the interfacebetween the electrode units, and the thickness, the porosity, and theloaded amount of the coating portion of each of the electrodes are notparticularly limited.

For example, the thicknesses of the positive electrode and the negativeelectrode included in the electrode assembly according to an embodimentof the present invention may be properly selected in consideration ofthe type of the electrode active material used, the battery capacitancefor realization, and the like. For example, in the electrode assemblyaccording to an embodiment of the present invention, the thickness ofthe positive electrode may be within a range of about 50 μm to about 150μm, about 80 μm to about 140 μm, or about 100 μm to about 150 μm, andthe thickness of the negative electrode may be within a range of about80 μm to about 200 μm, about 100 μm to about 200 μm, or about 100 μm toabout 150 μm.

Also, in the positive electrode and the negative electrode included inthe electrode assembly according to an embodiment of the presentinvention, the coated amount (may be referred to as loaded amount) perunit area is not particularly limited, and may be properly selected inconsideration of the type of the electrode active material used, thebattery capacitance for realization, and the like. For example, in thepresent invention, the coated amount per unit area of the positiveelectrode active material may be within a range of about 10 mg/cm² toabout 30 mg/cm², about 10 mg/cm² to about 25 mg/cm², or about 15 mg/cm²to about 30 mg/cm², and the coated amount per unit area of the negativeelectrode active material may be within a range of about 5 mg/cm² toabout 20 mg/cm², about 5 mg/cm² to about 15 mg/cm², or about 10 mg/cm²to about 20 mg/cm².

Also, in the positive electrode and the negative electrode, the porosityis not particularly limited, and may be properly selected according tothe type of the electrode active material used, the battery capacitancefor realization, and the like. For example, in the present invention,the porosity of the positive electrode may be within a range of about10% to about 30%, about 15% to about 30%, or about 10% to about 25%, andthe porosity of the negative electrode may be within a range of about15% to about 50%, about 20% to about 50%, or about 15% to about 40%.

According to the research of the inventors, when the thicknesses of thepositive electrode and the negative electrode included in the electrodeassembly are designed to satisfy the above-described conditions, whilethe area and/or thickness of each electrode unit are/or changedvariously, the electrode assembly having superior power efficiency andstructural stability, that is, the electrode assembly in which theelectrical capacitance when 500 charge and discharge cycles have beenperformed at 25° C. is 60% or more with respect to the electricalcapacitance after a single charge and discharge cycle, and the totalthickness variation ratio of the electrode assembly is 15% or less canbe obtained.

Meanwhile, the electrode units included in the electrode assemblyaccording to an embodiment of the present invention may be combinedvariously. Hereinafter, a configuration of an electrode unit accordingto an embodiment of the present invention will be described in detailwith reference to the accompanying drawings. FIGS. 1 through 4illustrate various embodiments showing configurations of electrode unitsin the electrode assembly according to an embodiment of the presentinvention.

FIG. 1 illustrates an electrode assembly including an electrode assemblyincluding electrode units comprised of stacked-type unit cells. Asillustrated in FIG. 1, the electrode assembly according to an embodimentof the present invention may include three types of electrode units 110,120, and 130 having different areas, and in this case, the electrodeunits may include stacked-type unit cells formed by stacking a positiveelectrode 40, a negative electrode 50 with a separator 60 interposedtherebetween. In this case, the respective electrode units may beconfigured as a single unit cell 105 like the electrode unit 130 or maybe configured as a combination of two or more unit cells 101 and 102 and103 and 104 having the same area like the electrode unit 110 and theelectrode unit 120. Meanwhile, in FIG. 1, the case in which all the unitcells constituting the electrode units are stacked-type unit cells isillustrated, but the present invention is not limited thereto. Namely,in an embodiment of the present invention, the electrode unit may becomprised of a jelly roll-type unit cell, a stacked-and-folded unitcell, besides the stacked-type unit cell, may be comprised of acombination of these unit cells and electrodes, and a combination ofdifferent types of unit cells.

For example, FIG. 2 illustrates an electrode assembly includingelectrode units comprised of a jelly roll-type unit cell and aelectrode. As illustrated in FIG. 2, the electrode assembly according toan embodiment of the present invention may include, for example, two ormore types of electrode units 210 and 220 having different areas, and inthis case, the electrode unit 210 having a relatively small area may becomprised of a jelly roll-type unit cell 201 and a single electrode 202,and the electrode unit 220 having a relatively large area may becomprised of a jelly roll-type unit cell 203. In this case, the jellyroll-type unit cells 201 and 203 are formed by winding a negativeelectrode sheet 50′ and a positive electrode sheet 40′ with a separator60′ interposed therebetween. In this case, in consideration of batterystability, the winding is performed such that the negative electrodesheet is positioned on an outer side, and the single electrode 202 is apositive electrode. However, the present invention is not limitedthereto and a jelly roll-type unit cell formed by winding such that thepositive electrode sheet is positioned at an outer side may be used, andin this case, an exposed portion includes an uncoated portion in which apositive electrode active material is not coated.

Meanwhile, FIG. 2 illustrates the electrode unit comprised of acombination of the jelly roll-type unit cell and the single electrodeand the electrode unit comprised of a single jelly roll-type unit cell,but the present invention is not limited thereto and a electrode unitmay be configured by combining a stacked-type unit cell and/or astacked-and-folded-type unit cell with a single electrode, or aelectrode unit may be configured by combining two or more types of unitcells.

For example, as illustrated in FIG. 3, the electrode assembly accordingto an embodiment of the present invention may be implemented bycombining a stacked-type unit cell and stacked-and-folded type unitcells. As illustrated in FIG. 3, the electrode assembly according to anembodiment of the present invention may include three types of electrodeunits 310, 320, and 330 having different areas, and in this case, theelectrode unit 310 having the smallest area and the electrode unit 330having the largest area may be comprised of stacked-type unit cells, andthe electrode unit 320 having a middle area may be comprised ofstacked-and-folded-type unit cells. Among these, the electrode unit 310having the smallest area may be comprised of a stacked-type unit cellhaving a structure of a negative electrode 50/separator 60/positiveelectrode 40/separator 60/negative electrode 50/separator 60/positiveelectrode 40, and the electrode unit 330 having the largest area may becomprised of a stacked-type unit cell having a structure of a negativeelectrode 50/separator 60/positive electrode 40/separator 60/negativeelectrode 50/separator 60/positive electrode 40/separator 60/negativeelectrode 50. In this manner, the electrodes disposed on both outermostsurfaces of the unit cell may be different or may be the same, and asingle unit cell may include one or more positive electrodes and/or oneor more negative electrodes. Meanwhile, the electrode unit 320 having amiddle area may be comprised of a stacked-and-folded-type unit cellformed by stacking electrode laminates including a negative electrode, apositive electrode, and a separator wound by a sheet-type separationfilm 70.

Meanwhile, FIG. 4 illustrates an example of an electrode unit configuredas a single electrode. As illustrated in FIG. 4, the electrode assemblyaccording to an embodiment of the present invention may include anelectrode unit 420 configured as a single electrode and an electrodeunit 410 comprised of one or more unit cells 401 and 402.

As above, in the electrode assembly according to an embodiment of thepresent invention, the single electrode unit may be configured as asingle electrode, one or more unit cells, or a combination thereof, andin this case, various unit cells, e.g., a stacked-type unit cell, ajelly roll-type unit cell, a stacked-and-folded-type unit cell and/or acombination thereof generally used in the art may be used as theforegoing unit cells without limitation. Meanwhile, besides the unitelectrodes illustrated in FIGS. 1 through 4, combinations of variouselectrode units may exist, and such modifications may be understood tobe included in the scope of the present invention.

Meanwhile, the electrode assembly according to an embodiment of thepresent invention may have a structure in which some or all of singleelectrodes and the unit cells constituting electrode units are wrappedwith a single sheet-type separation film. FIG. 5 illustrates animplementation example of the electrode assembly having a structure inwhich some or all of single electrodes and unit cells constitutingelectrode units are covered by a sheet-type separation film. Asillustrated in FIG. 5, the unit cells 501, 502, 503, 504, 505, 506, and507 constituting electrode units 510, 520, and 530 are covered with thesheet-type separation film 70, battery expansion is restrained by thesheet-type separation film 70, improving battery stability. Meanwhile,in FIG. 5, the sheet-type separation film may not be present in theportion indicated by the dotted line.

Meanwhile, FIG. 5 illustrates that the sheet-type separation film coversthe unit cells 501, 502, 503, 504, 505, 506, 507 in a zigzag manner, butthe present invention is not limited thereto and the method of winding asingle electrode and/or unit cells with a sheet-type separation film maybe variously implemented.

For example, as illustrated in FIG. 6, an electrode assembly accordingto an embodiment of the present invention may be fabricated by arrangingunit cells 601, 602, 602, 603, 604, 605, 606, and 607 having differentareas at appropriate intervals on the sheet-type separation film 70, androlling the sheet-type separation film 70.

Also, although not shown, an electrode assembly according to anembodiment of the present invention may be fabricated by arrangingpositive electrodes at certain intervals on one surface of thesheet-type separation film, arranging negative electrodes at certainintervals on the opposite surface, and subsequently rolling thesheet-type separation film. Or, an electrode assembly according to anembodiment of the present invention may be fabricated by preparing twosheet-type separation films, stacking negative electrodes in a certainarrangement on one sheet-type separation film, stacking positiveelectrodes in a certain arrangement on the other sheet-type separationfilm, and subsequently rolling the two sheet-type separation films.Besides, there may be various methods for wrapping some or all of theelectrode units by using a sheet-type separation film according to ashape, or the like, of an electrode assembly desired to be fabricated,and it should be appreciated that such modifications belong to the scopeof the present invention.

Meanwhile, a material of the positive electrode, the negative electrode,and the separator included in the electrode assembly according to anembodiment of the present invention is not particularly limited, andpositive electrodes, negative electrodes, and separators known in theart may be used without limitation. For example, the negative electrodemay be formed by coating a negative electrode active material such as alithium metal, a lithium alloy, carbon, petroleum cork, activate carbon,graphite, a silicon compound, a tin compound, a titanium compound, analloy thereof, or the like, on a negative electrode current collectormade of copper, nickel, aluminum, or an alloy including one or moretypes thereof. Also, the positive electrode may be formed by coating apositive electrode active material such as a lithium manganese oxide, alithium cobalt oxide, a lithium nickel oxide, a lithium iron phosphate,or a compound and a mixture including one or more thereof on a positiveelectrode current collector made of aluminum, nickel, copper, or acombination including one or more types thereof. In this case, the areasof the positive electrode and negative electrode constituting a singleunit cell in which the electrode active material is coated may be thesame or different. For example, the unit cells of FIG. 1 show the casein which the areas of the negative electrode and the positive electrodecoated with the electrode active material are the same, and the unitcells of FIG. 3 show a case in which the areas of the negative electrodeand the positive electrode coated with the electrode active material aredifferent. Also, the electrode active material may be coated on bothsurfaces of the current collector or may be coated only on one surfaceof the current collector in order to form an uncoated portion, or thelike.

Meanwhile, the separator may be a multi-layer film made of polyethylene,polypropylene, or a combination thereof having a micro-porous structure,or a polymer film for a gel-type polymer electrolyte or a solid polymerelectrolyte such as polyvinylidene fluoride, polyethylene oxide,polyacrylonitrile, or polyvinylidene fluoride hexafluoropropylenecopolymer may be used, but the present invention is not particularlylimited.

Also, in the electrode assembly according to an embodiment of thepresent invention, the electrode units may have one or more electrodetabs. In general, when the electrode unit is configured as a singleelectrode (e.g., 420 in FIG. 4), it may have only one electrode tab, andwhen the electrode unit is configured to include a unit cell, it mayinclude both a negative electrode tab and a positive electrode tab. Theelectrode tabs having the same polarity are electrically connected.Meanwhile, in an embodiment of the present invention, an area, anarrangement position, and the like, of the electrode tabs are notparticularly limited.

For example, the areas of the electrode tabs provided in the respectiveelectrode units may be the same or different. In the related art, sincethe areas of the electrode units included in an electrode assembly arethe same, electrode tabs having the same area are generally used. Incomparison, in the case of the present invention, since two or moretypes of electrode units having different areas are included, the sizesof electrode tabs optimized in every electrode unit may be different.Thus, in the electrode assembly according to an embodiment of thepresent invention, it may be more advantageous to select electrode tabshaving different areas according to the areas of electrode unit in orderto maximize electrical capacity.

Also, in an embodiment of the present invention, the electrode tabs maybe disposed in various positions. For example, the electrode tabs may bedisposed such that some or all of the electrode tabs having the samepolarity overlap with each other. In the case of the related artelectrode assembly, generally, the electrode tabs having the samepolarity are all disposed to overlap with each other in order tofacilitate electrical connection of the electrode tabs after beinginserted into a battery case. In this case, however, if the number ofstacked electrodes is increased, the thickness of the electrode tabs isincreased to degrade bondability between the electrode tabs. When theelectrode tabs are disposed such that only some, rather than all, ofthem overlap with each other, the foregoing problem can be considerablyreduced.

In particular, when two or more types of electrode units havingdifferent areas are used like the electrode assembly according to anembodiment of the present invention, electrode tabs having differentareas may be used according to areas of electrode unit and are arrangedsuch that only some thereof overlap with each other to enhancebondability of the electrode tabs while maximizing electrical capacity.FIG. 7 illustrates an implementation example of electrode tabs that maybe applicable to the electrode assembly according to an embodiment ofthe present invention. As illustrated in FIG. 7, in the electrodeassembly according to an embodiment of the present invention, electrodetabs 10, 20, and 30 having different areas are used according toelectrode units, and may be arranged such that only some thereof overlapwith each other.

Shapes of the electrode units according to an embodiment of the presentinvention may be the same or different. For example, the electrode unitsaccording to an embodiment of the present invention may have aquadrangular shape such as a rectangular shape, a square shape, atrapezoid shape, a parallelogram shape, a diamond-like shape, or thelike, or may have a quadrangular-like shape with chamfered corners orrounded corners, or may have a shape in which one or more sides areconfigured as curved lines. Besides, electrode units having variousother shapes may exist, and it should be appreciated that suchmodifications belong to the scope of the present invention.

Meanwhile, the electrode assembly according to an embodiment of thepresent invention may be formed by stacking electrode units having thesame shape, or may be formed by combining electrode units havingdifferent shapes as illustrated in FIG. 10. In this manner, since theelectrode units are formed to have various shapes, battery designshaving various shapes can be implemented and space utilization can beenhanced.

Meanwhile, in the electrode assembly according to an embodiment of thepresent invention, two or more types of electrode units having differentareas may be stacked to have various arrangements. A method for stackingelectrode units is not particularly limited. For example, as illustratedin FIGS. 8(A), (B), and (D), the electrode units may be stacked to havean arrangement in which the areas of the electrode units are reducedfrom a lower side to an upper side (or upwardly). As shown in FIG. 8(E),the electrode units may be stacked to have an arrangement in which theareas of the electrode units are increased from the lower side to theupper side. Also, as shown in FIG. 8(C), the electrode units may bestacked such that the electrode unit having the largest area is arrangedin a middle layer of the electrode assembly.

Also, in the electrode assembly according to an embodiment of thepresent invention, for example, as shown in FIG. 8(A), the electrodeunits may be stacked to have a stepwise arrangement in which one cornerof each of the respective electrode units is consistent. As illustratedin FIG. 8(B), the electrode units may be stacked to have a pyramid-typearrangement in which the central points of the respective electrodeunits in a planar direction are consistent. Also, as illustrated in FIG.8(D), the electrode units may be stacked to have an arrangement in whichthe central points of the respective electrode units in the planardirection are separated at certain intervals or irregularly. Besides,the stacking arrangement may be variously modified, and it should beappreciated that such various modifications belong to the scope of thepresent invention.

Hereinafter, a battery cell according to an embodiment of the presentinvention will be described. FIGS. 9 and 10 illustrate a battery cellaccording to an embodiment of the present invention. As illustrated inFIGS. 9 and 10, in a battery cell 900 according to an embodiment of thepresent invention, the electrode assembly 100 according to an embodimentof the present invention is installed in a battery case 910.

In this case, the battery case 910 may be a pouch-type case and may havea shape corresponding to that of the electrode assembly, but the presentinvention is not limited thereto.

Meanwhile, the pouch-type case may be made of a laminate sheet and, inthis case, the laminate sheet may include an outer resin layer formingthe outermost portion, a blocking metal layer preventing penetration ofa material, and an inner resin layer for hermetical sealing, but thepresent invention is not limited thereto.

Also, the battery case may have a structure in which electrode leads 920and 930 for electrically connecting electrical terminals of theelectrode units of the electrode assembly are exposed to the outside.Although not shown, an insulating film may be attached to upper andlower surfaces of the electrode leads 920 and 930 in order to protectthe electrode leads 920 and 930.

Also, the battery case may have a shape corresponding to a shape of theelectrode assembly. The shape of the battery case may be formed bydeforming the battery case itself. In this case, the shape and size ofthe battery case may not necessarily correspond to the shape and size ofthe electrode assembly. Namely, battery case may have a shape and sizesufficient to prevent an internal short circuit due to a thrustphenomenon. Meanwhile, the shape of the battery case is not limitedthereto and battery cases having various shapes and sizes may be used asnecessary.

The battery cell 100 according to an embodiment of the present inventionmay be a lithium ion battery or a lithium ion polymer battery, but thepresent invention is not limited thereto.

The battery cell 100 according to an embodiment of the present inventionmay be used alone or a battery pack including one or more battery cells100 may be used. The battery cell and/or the battery pack according toan embodiment of the present invention may be advantageously used invarious devices, for example, a portable phone, a portable computer, asmart phone, a smart pad, a net book, a light electronic vehicle (LEV),an electric vehicle, a hybrid electric vehicle, a plug-in hybridelectric vehicle, a power storage device, and the like. The structuresof these devices and fabrication methods thereof are known in the art,so a detailed description thereof will be omitted.

Meanwhile, when the battery cell or the battery pack is installed in theforegoing devices, a system component of the devices may be positionedin a surplus space formed due to the structure of the battery cell orthe battery pack. In an embodiment of the present invention, since thebattery cell or the battery pack is formed as the electrode assembly 1having a different size, the electrode assembly 1 itself is formed tohave a step. Thus, when the battery case is formed according to theshape of electrodes and installed in the devices, surplus space, whichis not provided in the conventional prismatic or oval battery cell orbattery pack, is formed.

When a system component of the device is installed in the surplus space,the system component of the device and the battery cell or the batterypack can be flexibly disposed, enhancing space utilization and reducingan overall thickness or volume of the device to implement a slim design.

MODES FOR CARRYING OUT THE INVENTION

Hereinafter, the present invention will be described in detail throughconcrete examples. It will, however, be understood that the followingexamples are provided only for describing embodiments of the presentinvention and are not intended to limit the present invention to thescope of the following examples.

Manufacturing Example 1: Positive Electrode A

LiCoO₂ was used as a positive electrode active material andpolyvinylidene fluoride (PVDF) was used as a binder, the positiveelectrode active material and the binder were dissolved inN-methyl-2-pyrrolidone (NMP) and then mixed to prepare a positiveelectrode paste. The positive electrode paste was coated on bothsurfaces of an aluminum foil collector having a thickness of 15 μm,dried in an oven at 150° C., and pressed to manufacture a positiveelectrode A. The manufactured positive electrode A had a thickness of100 μm, a porosity of 21%, and a reversible capacitance of 335 mAh.

Manufacturing Example 2: Positive Electrode B

A positive electrode B was manufactured using the same method as that inManufacturing Example 1 except that the thickness of the positiveelectrode became 110 μm. The manufactured positive electrode B had athickness of 110 μm, a porosity of 21%, and a reversible capacitance of375 mAh.

Manufacturing Example 3: Negative Electrode A

A blend material of natural graphite and artificial graphite was used asa negative electrode active material, and styrene-butadiene rubber (SBR)and carboxymethyl cellulose (CMC) carbon were used as a binder. Thenegative electrode active material and the binder were dissolved indistilled water and mixed to prepare a negative electrode paste. Afterthe negative electrode paste thus obtained was coated on both surfacesof a copper foil collector having a thickness of 10 μm, the copper foilcollector coated with the paste was thermally treated in an oven at 100°C., and pressed to manufacture a negative electrode A. The manufacturednegative electrode A had a thickness of 105 μm, a porosity of 27%, and areversible capacitance of 348 mAh.

Manufacturing Example 4: Negative Electrode B

A negative electrode B was manufactured using the same method as that inManufacturing Example 3 except that the thickness of the negativeelectrode became 108 μm. The manufactured negative electrode B had athickness of 108 μm, a porosity of 27%, and a reversible capacitance of359 mAh.

Manufacturing Example 5: Negative Electrode C

A negative electrode C was manufactured using the same method as that inManufacturing Example 3 except that the thickness of the negativeelectrode became 118.8 μm. The manufactured negative electrode C had athickness of 118.8 μm, a porosity of 27%, and a reversible capacitanceof 400 mAh.

Manufacturing Example 6: Negative Electrode D

A negative electrode D was manufactured using the same method as that inManufacturing Example 3 except that the thickness of the negativeelectrode became 90 μm. The manufactured negative electrode D had athickness of 90 μm, a porosity of 27%, and a reversible capacitance of294 mAh.

Manufacturing Example 7: Negative Electrode E

A negative electrode E was manufactured using the same method as that inManufacturing Example 3 except that the thickness of the negativeelectrode became 140 μm. The manufactured negative electrode C had athickness of 140 μm, a porosity of 27%, and a reversible capacitance of465 mAh.

Example 1

A small area electrode unit which was manufactured by cutting positiveelectrode A and negative electrode A to have a size of 80 mm×120 mm,interposing a separator therebetween and stacking the positive electrodeA, the separator, and the negative electrode A was stacked on a largearea electrode unit which was manufactured by cutting positive electrodeA and negative electrode A to have a size of 100 mm×150 mm, interposinga separator therebetween and stacking the positive electrode A, theseparator, and the negative electrode A to manufacture an electrodeassembly.

Example 2

A small area electrode unit which was manufactured by cutting positiveelectrode A and negative electrode B to have a size of 80 mm×120 mm,interposing a separator therebetween and stacking the positive electrodeA, the separator, and the negative electrode B was stacked on a largearea electrode unit which was manufactured by cutting positive electrodeA and negative electrode A to have a size of 100 mm×150 mm, interposinga separator therebetween and stacking the positive electrode A, theseparator, and the negative electrode A to manufacture an electrodeassembly.

Comparative Example 1

A small area electrode unit which was manufactured by cutting positiveelectrode B and negative electrode C to have a size of 80 mm×120 mm,interposing a separator therebetween and stacking the positive electrodeA, the separator, and the negative electrode B was stacked on a largearea electrode unit which was manufactured by cutting positive electrodeA and negative electrode B to have a size of 100 mm×150 mm, interposinga separator therebetween and stacking the positive electrode A, theseparator, and the negative electrode B to manufacture an electrodeassembly.

Comparative Example 2

An electrode unit which was manufactured by cutting positive electrode Aand negative electrode A to have a size of 80 mm×120 mm, interposing aseparator therebetween and stacking the positive electrode A, theseparator, and the negative electrode A was stacked on an electrode unitwhich was manufactured by cutting positive electrode A and negativeelectrode D to have a size of 100 mm×150 mm, interposing a separatortherebetween and stacking the positive electrode A, the separator, andthe negative electrode D to manufacture an electrode assembly.

TABLE 1 N/P Large area electrode unit Small area electrode unit N/Preversible N/P N/P thickness capacitance Positive Negative thicknessPositive Negative thickness ratio at ratio at Item electrode electroderatio electrode electrode ratio interface interface Example 1 A A 1.05 AA 1.05 1.05 1.03 Example 2 A A 1.05 A B 1.08 1.05 1.03 Comp. A B 1.08 BD 1.08 0.98 0.957 Example 1 Comp. A D 0.90 A A 1.05 0.90 0.878 example 2

Experimental Example 1

Electrical Capacitances and thickness variations of the electrodeassemblies which were manufactured by Examples 1 and 2 and ComparativeExamples 1 and 2 when the electrode assemblies were charged anddischarged 500 times were measured.

At this time, electrical capacitances were measured under the followingcharge and discharge conditions, and a pause of 10 minutes was providedbetween charge and discharge cycles.

(1) Charging condition: After a battery was charged to 4.2V or 4.35V ina constant current mode of 1 C, the constant current mode was convertedto a constant voltage mode, and the charging was completed after currentflowed until the amount of charged current became 1/20 of a minimumcapacitance of the battery.

(2) Discharge condition: A discharge current of 1 C flowed in theconstant current mode, and the discharge was completed when the voltagereached 3V.

The thickness variation ratio of the electrode assembly was calculatedby measuring a total thickness of the electrode assembly whenever asingle charge and discharge cycle was completed.

Measurement results are shown in FIG. 11. As shown in FIG. 11, it may beseen that the electrode assemblies of Examples 1 and 2 manufacturedaccording to the present invention have superior electrical capacitancesnot less than 80% even after 500 charge and discharge cycles, ascompared to the electrical capacitance after discharging single chargeand discharge cycle, and a thickness variation ratio of not more than10%, whereas the electrode assemblies of Comparative Examples 1 and 2experience abrupt electrical capacitance variation and thicknessvariation between 400 cycles and 500 cycles.

Experimental Example 2

A small area electrode unit was manufactured by respectively cuttingpositive electrode A and negative electrode E to have a size of 80mm×120 mm, interposing a separator and stacking the positive electrodeA, the separator and the negative electrode E.

Then, negative electrodes 1 to 8 were manufactured using the same methodas that in Manufacturing Example 3 except that the thickness of thenegative electrode was changed as shown in Table 2. Reversiblecapacitances of the manufactured negative electrodes 1 to 8 are found onTable 2. Then, large area electrode units 1 to 8 were manufactured byrespectively cutting positive electrode A and negative electrodes 1 to 8to have a size of 100 mm×150 mm, interposing a separator and stackingthe positive electrode A, the separator and the negative electrodes 1 to8.

After that, the small area electrode unit was stacked on the large areaelectrode units 1 to 8, respectively, to manufacture electrodeassemblies 1 to 8.

TABLE 2 Revers- ible Thick- Revers- Capaci- Thick- Large ness of ibletance ness area negative Poros- Capaci- ratio at ratio at negativeelectrode ity tance inter- inter- Item electrode (μm) (%) (mAh) faceface Electrode Negative 40 27 105 0.31 0.4 assembly electrode 1 1Electrode Negative 50 27 141 0.42 0.5 assembly electrode 2 2 ElectrodeNegative 80 27 251 0.75 0.8 assembly electrode 3 3 Electrode Negative110 27 360 1.07 1.1 assembly electrode 4 4 Electrode Negative 140 27 4651.39 1.4 assembly electrode 5 5 Electrode Negative 170 27 574 1.71 1.7assembly electrode 6 6 Electrode Negative 200 27 682 2.04 2.0 assemblyelectrode 7 7 Electrode Negative 220 27 753 2.25 2.2 assembly electrode8 8

After the electrode assemblies manufactured as above were charged anddischarged in a single cycle under the following charging conditions andthe discharging conditions, electrical capacitances and voltages weremeasured and the measured electrical capacitances were multiplied byvoltages to calculate electrical energies. Then, the calculatedelectrical energy values were divided by the volumes of the electrodeassemblies to calculate energy densities per unit volume.

(1) Charging conditions: After a battery was charged to 4.2V or 4.35V ina constant current mode of 1 C, the constant current mode was convertedto a constant voltage mode, and the charging was completed after currentflowed until the amount of charged current became 1/20 of a minimumcapacitance of the battery.

(2) Discharging conditions: A discharge current of 1 C flowed in theconstant current mode, and the discharging was completed when thevoltage reached 3V.

A pause time of 10 minutes was given between a single charge anddischarge cycle.

FIG. 12 is a graph showing energy densities with reversible capacitanceratios per unit area of negative electrodes and positive electrodes atan interface between electrode units based on the measured values, andFIG. 13 is a graph showing energy densities with thickness ratios perunit area of negative electrodes and positive electrodes at an interfacebetween electrode units.

From FIG. 12, it may be seen that the energy density per unit volume isvery high when the reversible capacitance ratio per unit area of thenegative electrode to the positive electrode at the interface betweenthe electrode units is in a range of 1 to 1.5, and particularly, 1 to1.2. Meanwhile, as shown in FIG. 12, even when the reversiblecapacitance ratio per unit area at the interface is not more than 1, acommercially available energy density may be obtained, but as reviewedin Experimental Example 1, since the electrical capacitance is abruptlyreduced and the thickness varies abruptly while the charge and dischargecycles are repeated, that case is not suitable for commercialization.

Also, from FIG. 13, it may be seen that when the thickness ratio of thenegative electrode to the positive electrode at the interface betweenthe electrode units is within a range of 0.5 to 2, the energy densityper unit volume is 300 Wh/l or more, a commercially available level,when the thickness ratio at the interface is within a range of 0.6 to1.9, the energy density per unit volume is 350 Wh/l or more and is veryexcellent, and when the thickness ratio at the interface is within arange of 0.8 to 1.5, particularly, 1.0 to 1.5, the energy density perunit volume is 400 Wh/l or more and is very excellent.

The invention claimed is:
 1. An electrode assembly comprising acombination of two or more types of electrode units having differentareas, the electrode units being stacked so as to form a stepped portiontherebetween, wherein a positive electrode and a negative electrode areformed to face each other at an interface between the electrode units,and Equation 4 is satisfied:dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1),  Equation 4: where n is an integernot less than 1, dN_(n) is a thickness of the negative electrode of theelectrode unit that is the n-th largest in area, dP_(n) is a thicknessof the positive electrode of the electrode unit that is the n-th largestin area, and dP_(n+1) is a thickness of the positive electrode of theelectrode unit that is the (n+1)th largest in area.
 2. An electrodeassembly of claim 1, wherein Equation 4-1 is satisfied:0.5≦dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1)≦2  Equation 4-1: where n is aninteger not less than 1, dN_(n) is a thickness of a negative electrodeof an electrode unit that is the n-th largest in area, dP_(n) is athickness of a positive electrode of an electrode unit that is the n-thlargest in area, and dP_(n+1) is a thickness of a positive electrode ofthe electrode unit that is the (n+1)th largest in area.
 3. The electrodeassembly of claim 1, wherein the positive electrode of the electrodeunit having a relatively small area faces the negative electrode of theelectrode unit having a relatively large area at the interface betweenthe electrode units having different areas.
 4. The electrode assembly ofclaim 1, wherein when 500 charge and discharge cycles have beenperformed at 25° C. under charging conditions (A) and a dischargingconditions (B), an electrical capacitance of the electrode assembly is60% or more of an electrical capacitance after a single charge anddischarge cycle, and a total thickness variation ratio of the electrodeassembly is 15% or less: charging conditions (A): after a battery ischarged to 4.2V or 4.35V in a constant current mode of 1 C, the constantcurrent mode is converted to a constant voltage mode, and the chargingis completed after current flows until the amount of charged currentbecomes 1/20 of a minimum capacitance of the battery; and dischargingconditions (B): a discharge current of 1 C flows in the constant currentmode, and the discharge is completed when the voltage reaches 3V.
 5. Theelectrode assembly of claim 1, wherein a ratio of a reversiblecapacitance per unit area of the negative electrode to a reversiblecapacitance per unit area of the positive electrode facing the negativeelectrode at the interface between the electrode units having differentareas is not less than
 1. 6. The electrode assembly of claim 1, whereinEquation 5 is satisfied:dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1) ≦dN _(n+1) /dP _(n+1) ≦dN _(n+1)/dP _(n+2)  Equation 5: where n is an integer not less than 1, dN_(n) isa thickness of the negative electrode of the electrode unit that is then-th largest in area, dN_(n+1) is a thickness of the negative electrodeof the electrode unit that is the (n+1)th largest in area, dP_(n) is athickness of the positive electrode of the electrode unit that is then-th largest in area, dP_(n+1) is a thickness of the positive electrodeof the electrode unit that is the (n+1)th largest in area, and dP_(n+2)is a thickness of the positive electrode of the electrode unit that isthe (n+2)th largest in area.
 7. The electrode assembly of claim 1,wherein Equation 5-1 is satisfied:0.5≦dN _(n) /dP _(n) ≦dN _(n) /dP _(n+1) ≦dN _(n+1) /dP _(n+1) ≦dN_(n+1) /dP _(n+2)≦2  Equation 5-1: where n is an integer not less than1, dN_(n) is a thickness of the negative electrode of the electrode unitthat is the n-th largest in area, dN_(n+1) is a thickness of thenegative electrode of the electrode unit that is the (n+1)th largest inarea, dP_(n) is a thickness of the positive electrode of the electrodeunit that is the n-th largest in area, dP_(n+1) is a thickness of thepositive electrode of the electrode unit that is the (n+1)th largest inarea, and dP_(n+2) is a thickness of the positive electrode of theelectrode unit that is the (n+2)th largest in area.
 8. The electrodeassembly of claim 6, wherein the electrode unit that is the (n+2)thlargest in area is disposed between the electrode unit that is the n-thlargest in area and the electrode unit that is (n+1)th largest in area,and Equation 6 is satisfied,dN _(n) /dP _(n+2) ≦dN _(n+1) /dP _(n+2)  Equation 6: where n is aninteger not less than 1, dN_(n) is a thickness of the negative electrodeof the electrode unit that is the n-th largest in area, dN_(n+1) is athickness of the negative electrode of the electrode unit that is the(n+1)th largest in area, dP_(n+1) is a thickness of the positiveelectrode of the electrode unit that is the (n+1)th largest in area, anddP_(n+2) is a thickness of the positive electrode of the electrode unitthat is the (n+2)th largest in area.
 9. The electrode assembly of claim1, wherein the electrode assembly comprises a combination of three ormore types of electrode unit having different areas, and the ratios ofthe reversible capacitances per unit area of the negative electrodes tothe reversible capacitances per unit area of the positive electrodesfacing the negative electrodes at the interface between the electrodeunits are the same as each other or increase as the contact area betweenthe electrode units is reduced.
 10. The electrode assembly of claim 1,wherein the positive electrode has a porosity in a range of 10% to 30%,and the negative electrode has a porosity in a range of 15% to 50%. 11.The electrode assembly of claim 1, wherein the electrode unit comprises:one or more single electrodes; one or more unit cells including at leastone positive electrode, at least one negative electrode, and at leastone separator; or any combination thereof.
 12. The electrode assembly ofclaim 11, wherein the unit cell is selected from the group consisting ofa jelly-roll type unit cell, a stacked-type unit cell, alaminated-and-stacked type unit cell and a stacked-and-folded-type unitcell.
 13. The electrode assembly of claim 1, wherein the electrodeassembly has a structure in which some or all of the single electrodeand the unit cells constituting the electrode units are wrapped with along sheet-type separation film.
 14. The electrode assembly of claim 11,wherein polarities of electrodes disposed on both outermost surfaces ofthe unit cell are the same.
 15. The electrode assembly of claim 11,wherein polarities of electrodes disposed on both outermost surfaces ofthe unit cell are different.
 16. The electrode assembly of claim 1,wherein a section of the electrode unit has a quadrangular shape, aquadrangular-like shape with at least one corner having a curved shape,or a shape with at least one or more sides having a curved shape. 17.The electrode assembly of claim 1, wherein the electrode assemblyincludes a combination of electrode units having different sectionalshapes.
 18. The electrode assembly of claim 1, wherein the electrodeassembly includes a combination of electrode units having the samesectional shape.
 19. The electrode assembly of claim 1, wherein theelectrode units include one or more electrode tabs, and the electrodetabs having the same polarity are connected.
 20. The electrode assemblyof claim 19, wherein the electrode tabs have different sizes.
 21. Theelectrode assembly of claim 1, wherein the electrode units are stackedto have an arrangement in which the areas of the electrode units arereduced upwardly.
 22. The electrode assembly of claim 1, wherein theelectrode units are stacked to have an arrangement in which the areas ofthe electrode units are increased upwardly.
 23. The electrode assemblyof claim 1, wherein the electrode units are stacked such that anelectrode unit having the largest area is arranged in a middle layer ofthe electrode assembly.
 24. The electrode assembly of claim 1, whereinthe electrode units are stacked to have an arrangement in which centralpoints of the respective electrode units in the plane direction areconsistent.
 25. The electrode assembly of claim 1, wherein the electrodeunits are stacked to have an arrangement in which the central points ofthe respective electrode units in the plane direction are spaced apartat certain intervals.
 26. The electrode assembly of claim 1, wherein theelectrode units are stacked to have an arrangement in which one cornersof the respective electrode units are consistent.
 27. A battery cell inwhich the electrode assembly of claim 1 is installed in a battery case.28. The battery cell of claim 27, wherein the battery case is formed tohave a shape corresponding to a shape of the electrode assembly.
 29. Adevice comprising one or more of the battery cells of claim
 27. 30. Thedevice of claim 27, wherein a system component of the device ispositioned in surplus space within the battery cell.
 31. The electrodeassembly according to claim 1, wherein thickness of the respectiveelectrode units are different.